Advanced abrasive-based nano-finishing processes: challenges, principles and recent applications

Kumar, Manjesh; Alok, Anupam; Kumar, Vikash; Das, Manas

doi:10.1080/10426914.2021.2001509

Cited by 18 publications

(9 citation statements)

References 160 publications

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“…Hardened steel Removing material from the surface of the material using sliding of abrasive particles of another material 0.184 µm Can deal with complex components [26,28,30] Elastic Emission Machining (EEM) silicon removing the material atom by atom with no cracks, deformation, or deep indentations Less than 0.0005 µm Removing material in loose abrasive-based machining [28,30,31] Chemical Mechanical Polishing (CMP) silicon…”

Section: Advanced Finishing Processmentioning

confidence: 99%

“…0.005 µm to 0.01 µm used in the finishing of the wafers made from silicon [28,30,32] Magnetic Abrasive Finishing (MAF) silicon nitride…”

Section: Advanced Finishing Processmentioning

confidence: 99%

“…Less than 0.01 µm Finishing the surface of nano-chips [28,30] Magnetorheological Finishing (MRF) Flat BG7 glass…”

Section: Advanced Finishing Processmentioning

confidence: 99%

“…The viscosity of this fluid is increased when it comes under the effect of the magnetic field. The CIPS arrange along the magnetic force line, and then the abrasive particles are entangled within the chains, and their motion causes the material removal Less than 0.001 µm Finishing micro/Nano-chips [28,30]…”

Section: Advanced Finishing Processmentioning

confidence: 99%

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Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Hashmi

Mali

Meena

et al. 2022

Metals

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Recent advances in technology and refinement of available computational resources paved the way for the extensive use of computers to model and simulate complex real-world problems difficult to solve analytically. The appeal of simulations lies in the ability to predict the significance of a change to the system under study. The simulated results can be of great benefit in predicting various behaviors, such as the wind pattern in a particular region, the ability of a material to withstand a dynamic load, or even the behavior of a workpiece under a particular type of machining. This paper deals with the mathematical modeling and simulation techniques used in abrasive-based machining processes such as abrasive flow machining (AFM), magnetic-based finishing processes, i.e., magnetic abrasive finishing (MAF) process, magnetorheological finishing (MRF) process, and ball-end type magnetorheological finishing process (BEMRF). The paper also aims to highlight the advances and obstacles associated with these techniques and their applications in flow machining. This study contributes the better understanding by examining the available modeling and simulation techniques such as Molecular Dynamic Simulation (MDS), Computational Fluid Dynamics (CFD), Finite Element Method (FEM), Discrete Element Method (DEM), Multivariable Regression Analysis (MVRA), Artificial Neural Network (ANN), Response Surface Analysis (RSA), Stochastic Modeling and Simulation by Data Dependent System (DDS). Among these methods, CFD and FEM can be performed with the available commercial software, while DEM and MDS performed using the computer programming-based platform, i.e., “LAMMPS Molecular Dynamics Simulator,” or C, C++, or Python programming, and these methods seem more promising techniques for modeling and simulation of loose abrasive-based machining processes. The other four methods (MVRA, ANN, RSA, and DDS) are experimental and based on statistical approaches that can be used for mathematical modeling of loose abrasive-based machining processes. Additionally, it suggests areas for further investigation and offers a priceless bibliography of earlier studies on the modeling and simulation techniques for abrasive-based machining processes. Researchers studying mathematical modeling of various micro- and nanofinishing techniques for different applications may find this review article to be of great help.

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Section: Advanced Finishing Processmentioning

confidence: 99%

“…0.005 µm to 0.01 µm used in the finishing of the wafers made from silicon [28,30,32] Magnetic Abrasive Finishing (MAF) silicon nitride…”

Section: Advanced Finishing Processmentioning

confidence: 99%

“…Less than 0.01 µm Finishing the surface of nano-chips [28,30] Magnetorheological Finishing (MRF) Flat BG7 glass…”

Section: Advanced Finishing Processmentioning

confidence: 99%

Section: Advanced Finishing Processmentioning

confidence: 99%

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Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Hashmi

Mali

Meena

et al. 2022

Metals

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“…Several innovations are being integrated into MRFF techniques regularly to improve the surface finish and surface quality. 6 In these MRFF methods, MRPF is utilized. In this fluid, iron particles (IPs) and abrasive particles (APs) are present.…”

Section: Introductionmentioning

confidence: 99%

Material removal analysis during MR polishing of complex gear teeth profiles

Kumar

Yadav

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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The geometric intricacy of tiny gears makes nano-finishing difficult. In the current study, the magnetorheological (MR) polishing process is used for the nano-finishing of intricate surfaces of tiny gear components uniformly. For polishing, the technique employs a dynamic fluid recognized as magnetorheological polishing fluid (MRPF), that has the ability to stiffen in the presence of a magnetic field. Base media, iron and abrasive particles are utilized to synthesize the MRPF. Permanent magnets produce the necessary magnetic field in the finishing zone. Finite element analysis (FEA) is utilized to model the iron and abrasive particles to understand better how they would react in the external magnetic field. FEA is utilized to analyze the magnetic flux density (MFD) distributions and the amount of magnetic force exerting on gear profiles through iron particles (IPs). It has been observed that the IPs present close to the active abrasives are primarily accountable for indenting active abrasives into the workpiece surfaces. In addition, the influence of particle dimension on the stiffness of iron particle chains in MRPF has been investigated. A mathematical model for material removal is developed by utilizing normal finishing force analysis on active abrasives. Lastly, the finishing surface characteristics of gear profiles are examined using an optical profilometer, field emission scanning electron microscope (FESEM) and spectroscopic analysis. Finally, 92.68% improvement in the surface finish is observed.

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Influence of Cerium Oxide Abrasive Particle Morphologies on Polishing Performance

Ni,

Fan,

Chen

et al. 2024

Cryst. Res. Technol.

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In this study, two morphologies of cerium oxide (CeO2) abrasive particles, octahedral and spheroidal, are synthesized by solvothermal method using cerium nitrate hexahydrate (Ce(NO3)3‐6H2O) as raw material. Fourier infrared spectroscopy, X‐ray diffractometer (XRD) and scanning electron microscopy (SEM) are used to characterize the composition and morphology of CeO2 abrasive particles. The synthesized CeO2 is used for chemical mechanical polishing (CMP) of the Si surface of 6H‐SiC wafers, and the surface morphology of the polished wafers are observed using atomic force microscopy (AFM). After polishing with octahedral and spheroidal abrasive particles, the surface roughness of the wafers are 0.327 and 0.287 nm, and the material removal rates (MRR) are 870 and 742 nm h−1, respectively. Calculations comparing the ultraviolet absorption spectra and bandgap energies of the two types of abrasive particles as well as molecular dynamics (MD) simulations reveal that the synthesized octahedral CeO2 particles possessed stronger surface chemical activity and material removal performance.

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Advanced abrasive-based nano-finishing processes: challenges, principles and recent applications

Cited by 18 publications

References 160 publications

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Material removal analysis during MR polishing of complex gear teeth profiles

Influence of Cerium Oxide Abrasive Particle Morphologies on Polishing Performance

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